Method and Apparatus for Monitoring and On-demand Lubricating of Industrial Valves

ABSTRACT

A method of monitoring industrial valve actuation and maintaining an industrial valve by lubricating it on-demand and in coordination with in-service valve operations through an automated system eliminating downtime and/or exposure of personnel to hazardous environments through centralized lubricant supply and spent fluid collections.

BACKGROUND OF THE INVENTION Cross-Reference to Related Applications

This application claims priority under 35 U.S.C. § 119(e) fromco-pending U.S. Provisional Patent Application No. 62/825,342, by JasonPitcher, “Method and Apparatus for Automatically Greasing Valves” filedMar. 28, 2019, which, by this statement, is incorporated herein byreference for all purposes.

FIELD OF THE INVENTION

The invention relates generally to maintenance of valves for control offluid flow. More particularly, the invention relates to automaticpreventative maintenance greasing, or lubricating, of industrial valvesin-service through coordination with regular operational valveoperations.

BACKGROUND OF THE INVENTION

Many industrial operations are dependent on the ability to control theflow of fluids. Valves are commonly used to control passage throughpipes and hoses as well as in/out of equipment, vessels, etc. Valvesregulate the flow of gasses, liquids, slurries, or loose materials(hereinafter collectively referenced as fluids) through an aperture orconduit such as a hose, tube, or pipe (hereinafter collectivelyreferenced as pipe or line), by opening, closing, or otherwiseinterrupting the path of flow.

Valves are manufactured by assembling multiple mechanical parts,primarily comprising: the body (an outer shell), trim (a combination ofreplaceable wetted parts), stem, bonnet (body end cap), and an actioningmechanism for applying a motive force (usually to a gate via the stem).Valves may be bifurcated into small bore sizes, generally 2 inches orless; and commercial/industrial valves, above 2 inches in diameter(generally designated as ‘Large Bore’).

Valves may be operated, or actioned, via rotating a stem with levers,and/or wheels (collectively called the valve ‘operator’). These arereferred to as ‘manual valves.’ Valves may also be actioned viaelectromechanical devices (‘actuators’) that may be electric, pneumatic,hydraulic, gas over oil, etc. and are collectively designated as‘actuated valves,’ which may optionally include a secondary manualoperator for safety.

A valve controls fluid flow and pressure by: stopping and starting fluidflow; varying fluid flow quantities, commonly referenced as‘throttling’; directing fluid flow directions, ‘switching’; regulatingdownstream pressure; and/or relieving excessive pressures or ‘venting’.Actuation of a valve may be through manual, hydraulic, pneumatic, orelectric application of motive forces. Examples of common types includethe ball valve, butterfly valve, globe valve, gate valve, plug valve,diaphragm valve, reducing valve, needle valve, check valve, andsafety/relief valve.

The force applied may require a quarter rotation of a valve stem as in aball valve, or require multiple complete revolutions, as in a globevalve. There may also be a need for application of a mechanical leveragesystem for force amplification in larger scale deployments. For example,a large wheel operator turning a worm screw against a gear positioningthe valve stein in a large bore valve controlling a viscous and/orhigh-pressure fluid line where the gate may be prone to resist movement.

Each valve type was designed for specific needs. Some valves are capableof throttling, while others can only start and stop flow. Some valvedesigns work well in corrosive systems, offer fine-control capabilities,and other valves are designed specifically for handling high pressure,caustics, abrasives, or combinations thereof. Each valve type, design,and final embodiment has certain inherent advantages and disadvantages.

There is a vast assortment of valve types to work with the diversity ofsystems, fluids, and environments in which the valves must operate.Choices for specific applications can be further influenced by pastindustry experience and knowledge, which is often collected and sharedin what is commonly referred to as ‘best practices.’ Consensus betweenindustry members to implement a subset of the ‘best practices’establishes an industry ‘standard,’ to which compliance is voluntary.

The American Petroleum Institute (API), American Society of MechanicalEngineers (ASME), and NSF International (formerly the “NationalSanitation Foundation”) are some of the organizations maintainingstandards for valve specifications. Because specifications often dependon industry member consensus and voluntary compliance, the duties andobligations required to comply are often minimalized as much astolerable to society. This can lead to eventual codification of thestandards by regulatory agencies, resulting in mandatory compliancerequirements with enforcement under penalty of law.

For simplicity in explanation and understanding, references herein willbe to API specifications for fluids in the O & G (Oil and Gas industry).Examples presented will focus on exploration and production processes,particularly emphasizing the inhospitable environment (as far as valvesare concerned) of high-pressure fracturing operations.

These O & G operations require fracturing fluids, comprised ofchemicals, abrasives, and high pressures, to be directed among extensivejunctions of equipment and along excessive distances with extensivecontrol exercised throughout to successfully accomplish the intendedtasks. Any exclusion should not be construed as non-applicable to theteachings herein, unless specifically designated as such.

The API ‘6A specification’ is the international standard for valvesspecific to wellhead and Christmas tree equipment, used in the petroleumand natural gas industries. API 6A valves are designed for the demandingenvironments of onshore and offshore drilling; production, pressure, andtemperature extremes; and heavy oil, sour, and subsea applications,including hydraulic fracturing operations incorporating pressure ratingsin excess of 20,000 PSI (pounds per square inch).

There are many valve types and designs that can safely accommodate thewide variety of industrial applications. But a gate valve is the typecommonly preferred in industrial piping. For simplicity, the discussionherein will be of a hydraulically actuated large bore gate valve (LBGV)unless otherwise indicated in the context. One skilled in the arts willappreciate the applications described herein to other valve types andactuators.

The most significant feature of gate valves is their low obstruction tothe fluid flow. Turbulence, like that caused by globe valves, causes adrop in the fluid's line pressure. When fluid is moving through longlengths of pipe, or when energy is being expended to increase pressureabove a threshold level for a particular task, it is important thatvalve selection does not decrease that pressure. When a gate valve iswide open, the gate, (or wedge) is positioned entirely out of the flowpath providing a straight passage through the valve body.

In the O & G industry pipelines are often measured in miles, and it canbe necessary to create fluid pressures greater than 5,000 PSI forcycling over a mile down a well bore to flush cuttings, power downholeequipment, or fracture rock formations. Here, a gate valve is thepreferred option over all other designs to avoid pressure drop in thelines. However, gate valves should only be used in the fully open orclosed positions; never for throttling purposes. Gates in intermediate,partially open, positions allow seals and seats to quickly erode as wellas creating noisy chatter that propagates along the line.

But more importantly, partially open gates may allow production fluidexposure to lubricating grease in the valve cavity. Force, heat, and/orchemicals can break down lubricant and washout the valve's body cavityleaving the stem, gate, and seats unlubricated and open to wear. This isespecially true in applications like high pressure frac operations wherechemicals and proppants are intentionally introduced into the fluid.

Unfortunately, transitioning between the open and closed states meansthat at least some of the time a gate will be partially open. Thisrequires maintenance in the form of lubrication to avoid more extensiverepairs and premature equipment failure. Lubricating/greasing valveshelps to reduce operating torque and protects against seizing, assist inproper seating and achieving manufacturer specified performance.

Each valve manufacturer provides grease fittings at key locations on thevalve body and provides instructions on valve maintenance. Thesemanufacturer-specified procedures and intervals are based on factors,such as but not limited to: design, construction, materials, lifeexpectancy, and cycling frequency.

But consumers set their maintenance procedure by adjusting the intervalsto account for application specific factors, such as: line pressure,valve positioning/uses, fluid type, lubricant type, etc. Each valvemanufacturer provides grease fittings, or lubrication ports at keylocations on the valve body and provides instructions on valvemaintenance.

For exemplary purposes, a theoretical valve has a grease fittingprotected by a grease fitting cap located on the bonnet flange for bodycavity lubrication, and another grease fitting on the bearing cap forthrust bearing lubrication. The manufacturer recommends body cavitylubrication every ten operating cycles, or monthly, whichever comesfirst.

Lubrication reduces friction between moving parts by substituting fluidfriction for solid fiction. Reducing friction reduces the amount ofenergy that is dissipated as heat and the amount of energy required toperform mechanical actions. Lubrication is a matter of vital importancethroughout industry. Automated lubrication systems exist to reduce theneed for someone to constantly run around the equipment with an oil canor grease gun in hand.

Automated lubrication systems supply a continuous flow of lubricant tobearings, shafts, pulleys, gears, etc. using different methods rangingfrom gravity fed wicks dripping oil, or spinning gears splashing oilaround a gear chamber, to pumps forcing lubricant under pressure intomechanical parts in measured quantities. Centralized lubrication systemsdispense lubricant from a supply reservoir by pumping it to dividervalves or metering injectors.

Metering injectors are sized to fill with fluid, and when triggered,inject the quantity of fluid into its connected lubrication point.Divider valves disperse lubricant received at frequent intervalsdirectly to each covered point, dividing the total quantity according toset ratios. Sizing of the injectors, or configuration of the dividerratios can be adjusted along with the frequency of the intervalsensuring proper lubrication of continuously operating equipment.

While sufficient for continuously operating machinery that can belubricated at regular intervals, or joints that can be lubricatedintermittently, these methods do not work for valves which requirespecific positions during lubrication, may require cycling, and mayrequire injection pressure monitoring. Additionally, continuouslubricators typically dispense lubricant in quantities measuring lessthan a cubic inch at pressures around 1,500 PSI. Valves require largerquantities of lubricant, holding approximately 1-2 pounds of grease perinch of bore size, possibly requiring injection at pressures more than2,000 PSI, depending on position and line pressure.

Typical frac operations use as much as 40,000 barrels of water, storedin holding tanks/trucks or a pond. The water is pumped by a HydrationUnit to a Blender truck and is mixed with chemicals supplied by a LAStruck (Liquid Additive System). This creates a ‘slime’ with theviscosity to suspend proppant, between 1.5-6 million pounds of grit orsand. Sand Kings (trucks or storage units for holding proppant) feed thegrit into the Blender for incorporation with the slime to produce fracfluid.

Frac fluid is fed through a manifold sled's, called the ‘Missile’, lowpressure lines to 8-15 High-Pressure Pump trucks. The trucks pressurizethe frac fluid and return it to the Missile to be directed down thewellbore. A Back-Pressure truck feeds back pressure to the well annularcountering the forces, to ease equipment strain, and containing fracfluid within the well.

The whole operation is monitored, recorded, and directed from a DataMonitoring van/truck to achieve fracking of target rock formations. Whenspent frac fluid returns through the annular it is directed by returnlines to Flowback tanks/ponds for recycling, injection, or disposal.

Large bore gate valves (LBGVs) are common in O & G production and usedextensively in hydraulic fracturing operations such as those describedabove. The required maintenance is dangerous to perform around thehigh-pressure lines but shutting down operations and relieving linepressure to allow lubrication is a costly option. Downtime must beminimized to meet schedules which typically allow 2-3 days for a jobbefore moving to the next scheduled well.

For a LBGV employed in a typical hydraulic fracturing operation(“frac-op”), lubricant is pumped into a first lubricant port, aninjecting port, filling the body cavity and flushing spent lubricant,fluids, and/or contaminants out of a second lubricant port. The lowerport may have a back-pressure tool so the new lubricant can approachoperating pressure. Alternatively, the second port may be closed firstso pressure can be applied through the injecting port. A hand operatedgrease pump may be sufficient to accomplish this job. However, lubricantquantity for the body cavity is dependent on the valve's bore size andpressure rating, often requiring over 20 lbs. of grease, more than manyhand pumps can deliver.

A typical frac-job utilizing only a single missile and the accompanyingentourage of: sand kings, storage tanks, hydration units, blendertrucks, pump trucks, etc. will require a conservative estimate of 50-70LBGVs to interconnect. These LBGVs will cycle a minimum of once duringevery frac-op and require maintenance every 4-7 cycles under mostcompany procedures.

This means that the typical frac-job requiring 20 frac-ops to completethe well, will result in a conservative estimate of 50 valves cycling 20times with 5 cycles between lubrications, each using a minimum of 25lbs. of grease, consumes literally more than 2 tons of grease.

${\frac{50_{valves} \times 20_{cycles}}{5_{\frac{cycles}{lubrication}}} \times 25_{\frac{{lbs}\mspace{11mu} {of}\mspace{11mu} {grease}}{lubrication}}} = {5\text{,}000\mspace{14mu} {lbs}\mspace{14mu} {of}\mspace{14mu} {grease}}$

What is needed is a way to monitor valve operations and automaticallylubricate the valves on-demand in synchronization with their normaloperation. This solution would allow preventative maintenance reducingcostly downtime and premature equipment failure and reduce the dangerousworking environments for maintenance personnel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a typical layout of O & G equipment to contain, mix,pressurize, and inject hydraulic fracturing fluids into a wellbore forhydraulic fracturing operations.

FIG. 2A illustrates a manually operated large bore gate valve for use intypical O&G operations.

FIG. 2B illustrates an option for monitoring physical operation of avalve, here through sensing movement of a valve's balancing stem.

FIG. 2C illustrates an actuated large bore gate valve with secondarymanual operation and balancing stem for use in typical O & G operation.

FIG. 2D illustrates an option for monitoring operation of a manualvalve.

FIG. 2E illustrates an option for monitoring physical operation of anactuated valve with a secondary manual operator.

FIG. 3A shows a centralized sequential lubrication system forintermittent lubrication of continuous operation devices.

FIG. 3B shows a centralized parallel lubrication system for intermittentlubrication of continuous operation devices.

FIG. 4 shows a centralized on-demand lubrication system in accordancewith an exemplary embodiment of the innovation.

FIG. 5 shows a centralized on-demand lubrication system, optionallycooperating with a control system, in accordance with an exemplaryembodiment of the innovation.

FIG. 6 shows a centralized on-demand lubrication system integrated witha valve control system, in accordance with an exemplary embodiment ofthe innovation.

FIG. 7 shows a method of on-demand lubrication by a flow control system,in accordance with an exemplary embodiment of the innovation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The innovation described herein automates valve maintenance bymonitoring valve operation and delivering lubricant on-demand accordingto actual usage and coordinating the lubrication of the valve within-service valve operations. This avoids downtime caused by taking avalve out-of-service for maintenance or more extensive repairs due toimproper maintenance.

The coordination with in-service valve operations also eliminateseffects of unnecessary (i.e. ‘maintenance only’) valve operations, andensure maintenance is performed in accordance with company procedure.Additionally, alleviating maintenance personnel from this routine tasklowers their exposure to hazards and increases their availability forother tasks.

Valve operations are monitored by a programmable logic controller thatalso controls delivery from a lubricant source to the valve. The logiccontroller delivers lubricant to the valve when operations require, andthe valve is in a condition to accept the lubricant. The requirementsfor accepting, and proper condition to accept, lubricant is dictated bythe specific valve and application environment.

In one embodiment the valve may be a plug valve which may be lubricatedin a full open or full close position but must be pressure monitored toavoid over pressurization and possible damage. In another embodiment,such as a sliding gate valve, the valve may need to be in either a fullopen or full close position but requires venting during lubricantinjection. Such valves often have upper and lower lubrication ports(grease fittings). One skilled in the art will understand greasefittings may be replaced by control valves on lubrication ports toautomate the regulation of lubricant or grease flow.

In one embodiment control valves, connected to lubrication ports, havethree states allowing the port to be: closed, connected to a lubricantsupply, or vented. In another embodiment a control valve may bethrottled to control lubricant delivery. In another embodimentthrottling may be accomplished by control of the pump regulatingdelivery pressure of the lubricant supply.

In another embodiment secondary controls may be positioned near thevalve and communicate to the controller through the sensor wiredcommunication medium employed by the controller to monitor valveactuation. In another embodiment the sensor communications and optionalsecondary controls may utilize a wireless communication medium.

An expansion of the preferred embodiment concerns cleaners and sealantsfor various valve types. In addition to controlling delivery from alubricant source, the fluid control equipment and controller may alsoprovide delivery from a secondary reservoir of other fluids such ascleaner. The controller being configured to optionally inject cleanerinto a valve, such as a floating ball valve, prior to introducinglubricant/sealant during maintenance to flush debris into the fluidflow. Further specifics should be obvious to one skilled in the arts andis beyond the scope of this application.

Another expansion concerns pressure locking of valves. A valve thattraps pressure within the body cavity may experience pressure lockingwhen line pressure decreases. In a pressure locked state, the valve isinoperable until body cavity pressure is relieved. Due to the highpressures involved, the equalizing procedures are considered dangerous,and is usually entrusted to skilled personnel exercising the utmostcare.

However, the innovation described here provides all necessary componentsfor safely venting the body cavity through a lubrication access portremotely from a safe distance without risk. It is recommended thatsafety procedures such as this be configured, as non-standard safetyroutines, into controller logic for use in such situations.

Another expansion concerns thermal binding of valves. A controller mayinclude a sensor monitoring temperature of the valve body. In conditionsof possible thermal binding, such as a temperature change greater than athreshold range occurring since the last valve actuation, the controllerbeing cognizant of possible binding can be configured to “bump” (providea short burst of motive power) the valve's actuator to disengage thecurrent limit switch prior to attempting to fully actuate the valve,possibly causing damage to the valve and/or actuator. In the event thelimit switch fails to engage, the controller may alert to the situationso personnel can heat the valve body to relieve the thermal bindingwithout damage.

In a typical frac operation, such as that described above, gate valvesmay require lubricating to prevent seal wear after every 2^(nd) or3^(rd) cycling, i.e. moving from full-open to full-close, or vice versa.High pressure in the lines makes it hazardous for personnel to be in thesurrounding area. The extensive number of valves complicates trackingmaintenance, and any downtime can be very costly.

in this environment, the preferred embodiment monitors valve operationand at prescribed intervals lubricates the valve according to setprocedures. In the embodiment presented here, the controller countsvalve cycles for each valve and upon exceeding a limit, attempts tolubricate the valve in a manner that is minimally disruptive to serviceoperations. Minimally disruptive may be determined by configuration ofthe controller, which may be cognizant of operations and have sufficientartificial intelligence to: cycle an unused valve as required, delay arequest for valve actuation for a limited period of time, or temporarilypostpone a maintenance lubrication. Such controller configuration isbeyond the current scope.

When lubrication is needed and the valve is positioned properly, here agate valve being in a full-open or full-close position, a lubricationport is opened venting spent fluids, the lubricant delivery sourcesupplies lubricant, injecting a specific quantity through anotherlubrication port, into the valve body, forcing the venting of the spentfluids. The venting lubrication port is closed, and the injectinglubrication port is pressurized as required, then closed, leaving thevalve serviced and operational.

In an alternative embodiment the lubricant delivery source iscentralized and supplies lubricant at low pressure to a plurality ofsecondary pumps which pressurize the lubricant for injection intoindividual valves. In one embodiment the low-pressure lubricant isdelivered in large quantity and secondary pumps increase pressure anddeliver high-pressure lubricant in a smaller quantity to supply anindividual valve, the tended valve. In another embodiment, a secondarypump may have a local reservoir sized according to the tended valve'slubricant requirements.

In one embodiment spent fluids are collected during venting from thevalve. In such an embodiment, the collection may be centralized suchthat the venting valves are interconnected and extended for finaldischarge into a centralized reservoir. In another embodiment, controlvalves may be used to route one lubrication port to the lubricant supplyand another lubrication port to the discharge collection allowingoptions for more efficient lubrication depending on, for instance, gateposition.

In the preferred embodiment, a programmable logic controller (acontroller) monitors valve position and determines lubrication needsindependent of manual operation or actuation by a second controller. Insuch an embodiment, sensors provide information to the controllerregarding valve operations.

These sensors may be unique to the controller or provide a shared signalto one or more controllers associated with the valve. In anotherembodiment the second controller may communicate with the firstcontroller. In a different embodiment the first and second controllersmay be a single controller to actuate the valve and control thelubrication.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a typical layout of O & G equipment to contain, mix,pressurize, and inject hydraulic fracturing fluids into a wellbore forhydraulic fracturing operations. The configuration of high-pressurehydraulic fracturing equipment (100) injects high-pressure fracturingfluids down a wellbore (110), to cause fracturing of rock formationsthousands of feet under the surface.

A pond, a large tank, or several smaller tanker trucks (185), as shownhere, supply water to a hydration unit (180) through water lines (155)where it is mixed with a chemical supply (156) from a liquid additivesystem, commonly referred to as a LAS truck (177), to create a supply ofslime (155).

The slime has higher viscosity than water allowing suspension ofsand/grit/abrasives known as proppant stored in several sand kings(174). A blender truck (170) mixes the supplied slime (155) with thesupply of proppant (157) to create fracturing fluid.

The fracturing fluid is supplied through low pressure lines (152) to amanifold sled, also known as a missile (160) for distribution to a fleetof high pressure fracturing pump trucks (165) which increase the fluidpressure as high as 20,000 PSI, and return the high pressure fluidthrough high pressure lines (125) to the missile (160) to collectivelybe injected (123) into the wellbore (110).

The high-pressure fluid is held in the wellbore (110) by balancingannular differential pressure by fluid back pressure (127) generated bya back-pressure truck (130). Completing a frac-op involves closing offhigh-pressure lines to the wellbore (123 and 127) to allow spent fluidup the wellbore (110) to the return line (154) to the flowback tanks(140) or holding pond.

The entire operation is managed from a data monitoring van (190) whichdirects composition, pressure, flow, hold, and return of fluids throughactuation of many valves (200), only a few of which are depicted here.

FIG. 2A illustrates a manually operated large bore gate valve for use intypical O&G operations. The valve (200) has a valve body (210)encircling a flow path interruptible/controllable by a gate (230),illustrated here in a full-open position. Other valves may interrupt theflow path in a more controllable manner through the positioning of aplate, disc, diaphragm, plug, or ball depending on the valve design.

The gate (230) connects to a stern (250), and an optional balancing stem(255) for actuation of the valve, here by a manual actuator (263, a handwheel). The stems (250 and 255) typically pass through bonnets (240)which provide access to the stems (250 and 255) and gate (230) withinthe body cavity (212) for extensive rework and heavy maintenance.

Upper lubrication ports (220) and lower lubrication ports (225), oftenincluding grease fittings, allow for the injection of lubricant into thebody cavity (212) for preventative maintenance. The lubricant attemptsto preserve gate seals, and seats, as well as the gate itself (230).

FIG. 2B illustrates an option. for monitoring physical operation of avalve, here through sensing movement of a valve's balancing stem. Thebalancing stem (255) projects through the bottom of the valve body, orlower bonnet (240). Actuation of the valve gate (230, previous FIG.)moves the connected stems (255 here and 250 previous FIG.) changing thesignals emitted through sensor wiring (282) by the sensors, shown hereas an upper limit sensor (285 a) and a lower limit sensor (285 b).

FIG. 2C illustrates an actuated large bore gate valve with secondarymanual operation and balancing stem for use in typical 0 & G operation.The valve (200) has a body (210, not indicated) which encircles a flowpath interruptible by a gate (230), illustrated here in a full-closedposition. Note the gate valve design is best suited for allowing orpreventing fluid flow and can be damaged if employed for extensiveperiods of flow regulation.

The gate (230) connects to a stem (250) for actuation of the valve by anactuator (260), here a hydraulic actuator (260) with a control line(280, not shown) connected to the hydraulic port (265), and withsecondary manual actuation through a manual actuator (263, a handwheel). The stem (250) is complimented by a balancing stem (255), andpasses through an upper bonnet (240) which provide access to the stems(250 and 255) and gate (230) within the body cavity (212, notdesignated) for extensive rework and heavy maintenance.

Upper lubrication ports (220) and lower lubrication ports (225), oftenincluding grease fittings, allow for the injection of lubricant into thebody cavity (212) for preventative maintenance.

FIG. 2D illustrates an option for monitoring operation of a manualvalve. The valve body (210, not designated) has an upper lubricationport (220) and lower lubrication port (225) for lubricating the gate(230) connected to the stem (250). The actuator's (260) motive power,manual operation by rotating the hand wheel (263), moves the stern (250)to activate an upper limit switch (285 a) or a lower limit switch (285b), sending a signal by wire (282) to a monitor.

Deactivating of one switch (285 a or 285 b) without activating the otherswitch (285 b or 285 a) indicates position along the travel (287),indicating the valve is partially engaged. This is an undesired positionfor a gate valve and may be detected by allowing a maximum time forvalve transition, with an optional alarm being raised by the monitor.

FIG. 2E illustrates an option for monitoring physical operation of anactuated valve with a secondary manual operator. The valve body (210,not designated) has an upper lubrication port (220) and lowerlubrication port (225) for lubricating the gate (230) connected to thestem (250). The actuator's (260) motive power control line (265) oroptionally manual operation of the hand wheel (263), moves the stern(250) to activate an upper limit switch (285 a) or a lower limit switch(285 b), sending a signal by wire (282) to a monitor. Deactivating ofone switch (285 a or 285 b) without activating the other switch (285 bor 285 a) indicates position along the travel (287), indicating partialengagement of the valve.

FIG. 3A shows a centralized sequential lubrication system forintermittent lubrication of continuous operation devices. Thiscontinuous automatic lubrication system cascades rations of lubricantfor sequential distribution among a plurality of devices periodically.The intermittent sequential lubrication system (300 a) has a pumpingunit (310) with a lubricant reservoir (312), a pressure pump (315) and apressure gauge (317). At regular programmed intervals a timer/controller(350) powers the pumping unit (310) delivering lubricant to the systemfor one or more cycles as designated by an end-of-cycle indicator (360).

The pumping unit (310) injects lubricant through supply lines (330) to ametering device (340), here a divider valve or divider (340 a). Thedivider (340 a) sequentially delivers metered quantities of lubricant toeach of its ports, cascading lubricant of unused ports to increase thequantity delivered to the next sequential port. The ports of the divider(340 a) may distribute fluid to supply lines (330) leading to additionaldividers (340 a) or to delivery lines (335) connected to fittings orbearings/joints/gears (305) serviced by the system.

FIG. 3B shows a centralized parallel lubrication system for intermittentlubrication of continuous operation devices. This lubrication systemmeters out measured quantities of lubricant to be simultaneouslyinjected in a plurality of device intermittently. The intermittentparallel lubrication system (300 b) has a pumping unit (310) with alubricant reservoir (312), a pressure pump (315) and a pressure gauge(317, not designated). At regular programmed intervals atimer/controller (350) powers the pumping unit (310) deliveringlubricant to the system for one or more cycles as designated by anend-of-cycle indicator (360), which in this case is a pressure sensor(360 a) and pressure relief trigger (360 b).

The pumping unit (310) injects lubricant through supply lines (330) tofeed metering devices (340), here metering injectors or injectors (340b). The injectors (340 b) independently collect and hold specificquantities of lubricant until pressure builds in the supply line (330)triggering the end-of-cycle indicator (360) to release the pressure. Therelief of pressure causes all injectors (340 b) to each deliver theircollected quantity of lubricant through delivery lines (335) connectedby fittings (370) to the individual bearings/joints/gears (305) servicedby the system.

FIG. 4 shows a centralized on-demand lubrication system in accordancewith an exemplary embodiment of the innovation. The on-demandlubrication system (300 c) has a programmable logic control unit, acontroller (400) monitoring actuation of a valve (200), here by amanually powered actuator (260) for positioning of the gate (230)through manipulation of the stem (250).

As the hand wheel (263) is operated, the gate's (230) travel (287) isindicated by signal lines (282) from the upper limit switch (285 a)and/or lower limit switch (285 b) positioned on the stem (250) to thecontroller (400). Once the valve's (200) gate (230) is in the fully openposition as indicated by the upper limit sensor (285 a), or the fullyclose position as indicated by the lower limit sensor (285 b),lubrication maintenance may occur if needed.

A solenoid control valve (410), controlled (415) by the controller(400), vents the valve body (210) through one of the lubrication ports(220 or 225), the ‘venting port,’ to a return line (337) leading to acentralize collection (312′). Though the embodiment here utilizes asolenoid control valve, specifically a solenoid operated directionalspool-type control valve, one skilled in the art will appreciate othercontrol options. A pressure pump (315) in a centralized lubricant pumpunit (310, not indicated) distributes lubricant through a supply line(330) where an optional secondary pump (430) increases lubricantpressure along a delivery line (335).

The delivery line (335) may be routed by another solenoid control valve(410) to another lubrication port (225 or 220), the ‘injecting port,’ todeliver a measured quantity of lubricant in accordance with the valve's(200) specifications. This inflow of pressurized lubricant through theinjecting lubrication port simultaneously forces the venting of spentfluids out through the venting lubrication port to the centralizedcollection (312′) through the return line (337).

One skilled in the art would appreciate that different valve designs mayallow for injecting lubricant simultaneous in more than one lubricationport, or that venting may occur through the flow pathway making ventingunnecessary. Further, one skilled in the art would appreciate that ameasured quantity of lubricant may not be a specific quantity, but anundetermined amount required to achieve a desired pressure change at thelubrication port, which may be detected by monitor of the supply line ordelivery lines.

FIG. 5 shows a centralized on-demand lubrication system, optionallycooperating with a control system, in accordance with an exemplaryembodiment of the innovation. This embodiment of an on-demandlubrication system (300 c′) has a programmable logic control unit, acontroller (400) monitoring actuation of the valve (200), controlled bya remote valve controller (460) through motive power (265) to anactuator, here a hydraulic actuator (260) with secondary manualactuation through a hand wheel (263).

The remote valve controller (460) may optionally communicate (440) withthe controller (400), and/or may also monitor actuation of the valve(200) through shared (282′) signal lines (282) from the limit switches(285 a and 285 b). Once the valve (200) is in the fully open position asindicated by movement of the stem (250) to engage the upper limit sensor(285 a), or the fully close position as indicated by engagement of thelower limit sensor (285 b), lubrication maintenance may occur as needed.

A solenoid control valve (410), controlled (415) by the lubricationsystem's controller (400) vents one of the valve's (200) lubricationports (220 or 225, not indicated), the ‘venting port,’ to a return line(337) leading to a centralize collection (312′). A pressure pump (315)in a centralized lubricant pump unit (310, not indicated) distributeslubricant from the lubricant reservoir (312) through a supply line (330)where an optional secondary pump (430) may be used to increase lubricantpressure along a delivery line (335). The secondary pump (430) may alsoincorporate a local reservoir to prevent starvation of lubricant byother valves in a multi-valve system employing the centralize lubricantsupply reservoir (312).

The delivery line (335) may be routed by another solenoid control valve(410) to another lubrication port (225 or 220, not indicated), the‘injecting port,’ to deliver a measured quantity of lubricant inaccordance with the valve's (200) specifications. This inflow ofpressurized lubricant through the injecting lubrication portsimultaneously forces the venting of spent fluids out through theventing lubrication port to the centralized collection (312′) throughthe return line (337), as discussed above.

In this embodiment the communication (440) between controllers (400 and460) may allow predictive use of the centralized pressure pump (315)ensuring sufficient pressure for feed lines (330), eliminating the needfor separate delivery lines (335) and secondary pumps (430) by ensuringmultiple valves (200) will not simultaneously lubricate, over taxing ashared pump unit (310, not designated). Alternatively, communicationbetween multiple lubrication controllers (400) through a centralcontroller (460) may allow problems of simultaneous demands to bemitigated by adjusting logic control accordingly.

FIG. 6 shows a centralized on-demand lubrication system integrated witha valve control system, in accordance with an exemplary embodiment ofthe innovation. This embodiment of an on-demand lubrication system (300c″) has a single programmable logic control unit, a controller (400)actuating the valve (200) and monitoring actuation in case of manualactuation.

The controller (400) monitors signal lines (282) from the limit switches(285 a and 285 b) to determine lubrication needs, for instance bymonitoring the time necessary for an actuator (260) to physically move avalve. Increased time from deactivation of one limit switch (285 a or285 b) to activation of the other limit switch (285 b or 285 a) mayindicate a need for maintenance.

The controller (400) also controls (415) solenoid control valves (410),a pump unit's (310, not indicated) pressure pump (315), and optionalsecondary pump (430) for distribution (330) and delivery (335) of from alubricant reservoir (312), and collection (337) to a centralizecollection reservoir (312′) of spent fluids.

FIG. 7 shows a method of on-demand lubrication by a flow control system,in accordance with an exemplary embodiment of the innovation. Theon-demand automatic lubrication system provides monitoring and analysisfor timely high-pressure delivery of lubrication coordinated within-service valve operations to eliminate downtime or the effect ofextraneous valve operations. The flow control system (700) has aprogrammable logic control unit, a controller (400), monitoringactuation of a plurality of valves (200 a -c), and providing motivepower (265) to actuators (260) to independently actuate the valves (200a-c).

Monitoring actuation of the valves (200) through signal lines (282) fromthe limit switches (285 a and 285 b) provide information on individualvalve usage, and position for purposes of maintenance lubrication. Thecontroller (400) may consider an individual valve's performance, pastusage, maintenance history, anticipated usage, etc. to prioritizemaintenance lubrications.

The controller (400) controls (437) a pressure pump (315) of thecentralized lubrication pump unit (310) delivering lubricant at lowpressure from a lubricant reservoir (312) in large quantities through asupply line (330) to secondary pump (430) controlled (435) by the samecontroller. The secondary pump (430) increases lubricant pressure fordelivery (335) to a lubricant port (220), the injecting port.

A second lubricant port (225) is opened to vent fluids, a venting port,allowing the injection of lubricant to force venting of spentfluids/lubricant through the return line (337) to the collectionreservoir (312′). Pressure of spent fluids exiting the venting port willgravitate to the unpressurized collection reservoir (312′) but may alsobe aided by additional pumps to assist flow.

In one embodiment, the secondary pump (430) increases pressure byreducing the volume of the delivered lubricant. In such a system, the“large quantities” of the supply line are dictated by the consumption ofa maximum number of secondary pumps (430) to be concurrently supported.In another embodiment, the secondary pumps (430) have local reservoirsfor collecting sufficient lubricant required to lubricate a valve (200).In another embodiment, the secondary pump's (430) local reservoir maybuffer the lubricant from the supply line. In another embodimentthrottling lubricant flow to one or more valves extends the service timein exchange for an increase in concurrent operations.

One skilled in the art would appreciate the considerations for balancingthe large quantities of lubricant in the supply line against theconcurrent demands of a plurality of concurrent valve lubrications withor without local reservoirs, and other factors for configuration of thesystem and its controller (400) for proper limiting and prioritizing ofvalve lubrications to yield a desired system performance.

The diagrams in accordance with exemplary embodiments of the presentinnovation are provided as examples and should not be construed to limitother embodiments within the scope of the innovation. For instance,quantities, distances, and volumes may not be to scale and should not beconstrued to limit the innovation to the particular proportions.Additionally, some elements illustrated in the singularity may actuallybe implemented in a plurality, and those illustrated in the pluralitycould vary in actual count. Some elements illustrated in one form,design, or configuration may vary in detail from that depicted. Further,specific information should be interpreted as illustrative fordiscussing exemplary embodiments and is not provided to limit theinnovation.

The above discussion is meant to be illustrative of the principles andvarious embodiments of the present innovation. Numerous variations andmodifications will become apparent to those skilled in the art once theabove disclosure is fully appreciated. It is intended that the followingclaims be interpreted to embrace all such variations and modifications.

What is claimed is:
 1. An apparatus for lubricating an industrial valvecomprising: a lubricant delivery source comprising: a lubricantreservoir, an optional lubricant sensor, and a first pump; lubricanttubing; at least one industrial valve, comprising: a valve bodyencircling a flow path interruptible by, a gate attached to a stem movedby, an actuator to actuate the industrial valve between: an open, firstgate position, and a closed, second gate position for controlling theflow path of the industrial valve; and one or more grease fittings forlubrication of the industrial valve; and a controller configured to:monitor actuation of the industrial valve or position of the gate; andselectively deliver lubricant from the lubricant reservoir, through thelubricant tubing, to one or more grease fittings on the valve body. 2.The apparatus as described in claim 1 wherein the lubricant sensordetermines the pressure of lubricant delivered.
 3. The apparatus asdescribed in claim 1 wherein the lubricant sensor determines thequantity of lubricant delivered.
 4. The apparatus as described in claim1 wherein the controller is further configured to: record actuation ofthe industrial valve; count movement of the gate from one position toanother position, a valve cycle; monitor gate position; or actuate theindustrial valve.
 5. The apparatus as described in claim 1 whereinselectively pumping lubricant from the lubricant reservoir is responsiveto a specific gate position.
 6. The apparatus as described in claim 4wherein selectively pumping lubricant from the lubricant reservoir is:responsive to actuation of the industrial valve, or concurrent with anactuation of the industrial valve.
 7. The apparatus as described inclaim 1 further comprising: a second pump: receiving lubricant from thelubricant tubing, pressurizing the lubricant, high-pressure lubricant,and delivering the high-pressure lubricant, to the one or more greasefittings for lubrication of the industrial valve.
 8. The apparatus asdescribed in claim 1 wherein the controller is further configured toopen a second grease fitting, and vent excess fluid from the valve bodywhile pumping lubricant from the lubricant reservoir.
 9. The apparatusas described in claim 1 further comprising: one or more control valves,selectively directing high-pressure lubricant to one of the one or moregrease fittings of the industrial valve, and directing excess fluid froma second of the one or more grease fittings of the industrial valve to adischarge collection.
 10. The apparatus as described in claim 1 thedischarge collection further comprising: a discharge reservoir forcollecting excess fluid, optional hose connecting the industrial valveto the discharge reservoir.
 11. A system for lubricating an industrialvalve comprising: monitoring movement of a gate in an industrial valve,controlling a lubrication system to deliver (at high pressure)lubrication, greasing the industrial valve by pumping lubricationthrough a grease fitting for, distributing throughout a cavity of thevalve by movement of the gate.
 12. A method of lubricating a valvecomprising: monitoring operation of the valve; responsive to the valveoperations and position, delivering a prescribed quantity of lubricantto a first grease connection on the valve, while simultaneously ventingexcessive pressure and collecting discharge from a second greaseconnection on the valve.
 13. The method as described in claim 1, whereinthe delivering of lubricant is coordinated with regular in-service valveoperations.
 14. The method as described in claim 1, further comprising:monitoring operation of other valves; coordinating delivery of lubricantamong the plurality of valves.
 15. The method as described in claim 1,wherein the delivery of lubricant is further responsive to anticipatedfuture valve operations.